Modular sidewall for passenger vehicle

ABSTRACT

A modular sidewall for a passenger vehicle. The modular sidewall comprises an outer frame, and a plurality of individual sections configured to be secured together at least partially within the outer frame. The plurality of individual sections includes a main section presenting at least one window opening configured to receive a window, and a standard section presenting at least one window opening configured to receive a window. The said standard section has a width that is smaller than a width of said main section. The modular sidewall may also include a seat rail for supporting one or more seats within the passenger vehicle.

FIELD

Embodiments of the present invention generally relate to passengervehicles. More specifically, embodiments of the present invention aredirected to a modular sidewall for passenger vehicles, with certain ofsuch modular sidewalls including seat rails.

BACKGROUND

Passenger vehicles, such as vans, shuttles, busses, and the like, areoften utilized to transport passengers between geographic locations.Depending on the need, passenger vehicles can be manufactured in varioussizes so as to transport various numbers of passengers. For example,common passenger vehicles have lengths anywhere between 15 and 30 feet,or more. In general, the components used to manufacture a passengervehicle of a specific size are uniquely formed according to thespecification for the particular passenger vehicle. As such, componentsused to manufacture a passenger vehicle of a specific size cannot begenerally used in the manufacture of a passenger vehicle of a differentsize. For instance, a sidewall used to manufacture a 20 foot passengervehicle would generally be specifically made for the 20 foot passengervehicle, and would not be usable for the manufacture of a 27 footpassenger vehicle.

In addition, generally all passenger vehicles include seat railsextending along the inboard sides of vehicles' sidewalls. Such seatrails function to support the seats within the passenger compartment ofthe passenger vehicles. In the past such seat rails were generallydifficult to manufacture and integrate with the sidewalls.

Accordingly, a need exists for a modular sidewall for passengervehicles, with the modular sidewall including modular sections that canbe configured as necessary to be incorporated as part of passengervehicles of generally any size. In addition, there is a need for a seatrail that can be efficiently manufactured and assembled as part ofpassenger vehicle sidewalls.

SUMMARY

Embodiments of the present invention include a modular sidewall for apassenger vehicle. The modular sidewall comprises an outer frame, and aplurality of individual sections configured to be secured together atleast partially within the outer frame. The plurality of individualsections includes a main section presenting at least one window openingconfigured to receive a window, and a standard section presenting atleast one window opening configured to receive a window. The standardsection has a width that is smaller than a width of the main section.

Embodiments of the present invention additionally include a method ofmanufacturing a modular sidewall for a passenger vehicle. The methodcomprises the initial step of providing an outer frame. The methodincludes the additional step of securing a plurality of individualsections together within the outer frame to form the modular sidewall.The plurality of individual sections includes a main section presentingat least one window opening configured to receive a window, and astandard section presenting at least one window opening configured toreceive a window. The standard section has a width that is smaller thana width of the main section. The method further includes securing themodular sidewall to a side of the passenger vehicle.

This summary is not intended to identify essential features of thepresent invention, and is not intended to be used to limit the scope ofthe claims. These and other aspects of the present invention aredescribed below in greater detail.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention are described in detail below withreference to the attached drawing figures, wherein:

FIG. 1 is a perspective view of a structural frame of a passengervehicle with a pair of modular sidewalls formed according to embodimentsof the present invention;

FIG. 2 is a perspective view of a modular sidewall from the passengervehicle of FIG. 1;

FIG. 3 is an exploded view of the modular sidewall from FIG. 2;

FIG. 4 is a perspective view of a standard window section from themodular sidewall from FIGS. 2-3;

FIG. 5 is a perspective view of a contracted window section from themodular sidewall from FIGS. 2-3;

FIG. 6 is a perspective view of another contracted window section fromthe modular sidewall from FIGS. 2-3;

FIG. 7 is a perspective view of a support section from the modularsidewall from FIGS. 2-3;

FIG. 8 is a perspective view of a main section from the modular sidewallfrom FIGS. 2-3;

FIG. 9 is a cross section taken along the line 9-9 from FIG. 2,particularly illustrating a spot weld connecting side elements fromsections of the modular sidewall;

FIG. 10 is a perspective view of an additional embodiment of a mainsection, particularly illustrating the main section including a wheelwell;

FIG. 11 is a cross section taken along the line 11-11 from FIG. 2,particularly illustrating a seat rail from the modular sidewall; and

FIG. 12 is a perspective view of another modular sidewall from thepassenger vehicle of FIG. 1, particularly illustrating gaps presentedfor receiving a door and/or a wheelchair lift.

The figures are not intended to limit the present invention to thespecific embodiments they depict. The drawings are not necessarily toscale.

DETAILED DESCRIPTION

The following detailed description of embodiments of the inventionreferences the accompanying figures. The embodiments are intended todescribe aspects of the invention in sufficient detail to enable thosewith ordinary skill in the art to practice the invention. Otherembodiments may be utilized and changes may be made without departingfrom the scope of the claims. The following description is, therefore,not limiting. The scope of the present invention is defined only by theappended claims, along with the full scope of equivalents to which suchclaims are entitled.

In this description, references to “one embodiment”, “an embodiment”, or“embodiments” mean that the feature or features referred to are includedin at least one embodiment of the invention. Separate references to “oneembodiment”, “an embodiment”, or “embodiments” in this description donot necessarily refer to the same embodiment and are not mutuallyexclusive unless so stated. Specifically, a feature, structure, act,etc. described in one embodiment may also be included in otherembodiments, but is not necessarily included. Thus, particularimplementations of the present invention can include a variety ofcombinations and/or integrations of the embodiments described herein.

Embodiments of the present invention are directed to a modular sidewall,and components thereof, for passenger vehicles. A structural frame 10 ofa passenger vehicle is illustrated in FIG. 1. The structural frame 10includes a floor subassembly 12, a roof subassembly 14, a backwall 16, acab subassembly 18, and a pair of modular sidewalls 20, 21. Asillustrated, the modular sidewalls 20, 21 extend from generally from thefloor subassembly 12 to the roof subassembly 14 and from the backwall 16to the cab subassembly 18. In some embodiments, a portion of one or moreof the modular sidewalls 20, 21 may extend into the cab subassembly 18so as to form a part of the cab subassembly 18. It should be understoodthat the structural frame 10 shown in FIG. 1 is provided simply forillustration, and other modular sidewall embodiments are contemplatedfor use with other passenger vehicles of smaller and larger sizes.Regardless, the modular sidewalls of embodiments of the presentinvention are configurable to be used as part of passenger vehicles ofvarious sizes, as will be described in more detail below.

As used herein the terms “front” or “forward” refer to a direction fromthe backwall 16 or rear the passenger vehicle toward the cab subassembly18 or front of the passenger vehicle, while the terms “back,” “rear,” or“rearward” refer to a direction from the cab subassembly 18 or front ofthe passenger vehicle toward the backwall 16 or rear of the passengervehicle. Similarly, the terms “upward” or “higher” refer to a directionfrom the floor subassembly 12 or bottom of the passenger vehicle towardsthe roof subassembly 14 or top of the passenger vehicle, while the terms“downward” or “lower” refer to a direction from the roof subassembly 14or top of the passenger vehicle to the floor subassembly 12 or bottom ofthe passenger vehicle. Finally, the terms “inward” or “inboard” refer toa direction towards a longitudinal centerline of the passenger vehicle,while the terms “outward” or “outboard” refer to a direction away fromthe longitudinal centerline of the passenger vehicle.

With reference to FIGS. 2-3, an embodiment of a modular sidewall 20 isshown in more detail. As illustrated, the modular sidewall 20 maycomprise one or more individual modular sections, such as a central mainsection 22, one or more a standard window sections 24, one or morecontracted window sections 26, and one or more support section 28. Incertain additional embodiments, the modular sidewall 20 may include aseat rail 30 that extends in a generally horizontal manner across theinboard side of the individual modular sections of the modular sidewall20. As will be described in more detail below, the individual modularsections of the modular sidewall 20 may be secured together via variousmethods of attachment or connection components, such as via riveting,fillet welding, and/or spot welding. In addition, the individual modularsections may be secured to an outer frame section 32 that includes ahorizontally-extending top element 34 and a pair of vertically-extendingside elements 36 that extend downward from ends of the top element 34.As such, the individual modular sections may be retained within thespace presented between the top element 34 and the side elements 36 ofthe frame section 32. Although the following description provides forvarious components of the modular sidewall 20 to be secured together viawelding or spot welding, it should be understood that embodiments mayprovide for other securement components to be used in place of spotwelds, such as rivets, fillet welds, or the like.

Beginning with the frame section 32, as illustrated in FIG. 3, the topelement 34 may be formed as an elongated section of rectangular orsquare steel or other metal tubing. In some embodiments, the tubing ofthe top element 34 may have dimensions approximately equal to 2.0×1.5inches (i.e., width×width). A length of the top element 34 may varydepending on the size of the passenger vehicle, but in some embodimentsmay be between 8 and 32 feet, between 10 and 24 feet, between 12 and 20feet, or about 16 feet, or about 18 feet. Similarly, the side elements36 of the frame section 32 may be formed from rectangular or squaresteel or other metal tubing. In some embodiments, the square tubing ofthe side element 36 may have dimensions approximately equal to 1.5×1.5inches (i.e., width×width). In other embodiments, the side element 36may have dimensions approximately equal to 3.0×1.5 inches (i.e.,width×width). As shown in the drawings, some embodiments may provide forthe forward side element 36 to be formed from 1.5×1.5 inch steel tubing,while the rearward side element 34 may be formed from 3.0×1.5 steeltubing. A length of the side element 34 may vary depending on the sizeof the passenger vehicle, but in some embodiments may be between 48 and96 inches, between 60 and 84 inches, or about 72 inches. As such, anoverall height of the frame section 32 may be about 72 or 73 inches. Theside elements 36 may be secured to the top element 34 by various methodsof attachment, such as by riveting, fillet welding, or spot welding.

Turning to the standard window section 24, as illustrated in FIG. 4, thestandard window section 24 may be formed as a generally rectangularframe comprising a horizontal top element 40, a horizontal bottomelement 42 and a pair of vertical side elements 44 extending betweenends of the top element 40 and the bottom element 42. The top element 40may be formed as an elongated section of steel or other metal c-channel(e.g., galvanized steel), with the channel portion of the c-channelfacing downward. As used herein, the term c-channel is used to mean asection of material including a primary section presenting a width ofthe section, and a pair of flange sections extending in parallel and inthe same direction from opposite edges of the primary section. As such,the c-channel can present a channel between the primary section andflange sections. In some embodiments, the top element 40 may havedimensions approximately equal to 1.25×0.75 inches (i.e., width×flangelengths). The top element 40 of the standard window section 24 may beformed with various lengths; however, certain embodiments may providefor the lengths to be between 24 and 72 inches, between 36 and 60inches, or about 48 inches. In some embodiments, the top element 40 ofthe standard window section 24 may be formed in a generally standardsize of about 48 inches.

The bottom element 42 of the standard window channel may be formed as anelongated section of steel or other metal z-channel (e.g., galvanizedsteel). As used herein, the term z-channel is used to mean a section ofmaterial including a primary section presenting a width of the section,and a pair of flange sections extending in parallel but in oppositedirections from opposite edges of the primary section. With reference toFIG. 4, the upward-extending flange element of the bottom element 42 maybe positioned on an inboard side of the standard window section 24 (alsoillustrated in FIG. 2), while the downward-extending flange element ofthe bottom element 42 may be positioned on an outboard side of thestandard window section 24. In some embodiments, the z-channel of thebottom element 42 may have dimensions approximately equal to 1.5×1.5×1.5inches (i.e., width×upward-extending flange length×downward-extendingflange length). The bottom element 42 of the standard window section 24may be formed with a length that generally corresponds with or is equalto the top element 40. In some embodiments, the bottom element 42 of thestandard window section 24 may be formed in a standard size of about 48inches.

The side elements 44 of the standard window section 24 may be formed aselongated sections of steel or other metal c-channel (e.g., galvanizedsteel), with the channel portions of the c-channels facing inwardstowards each other. In some embodiments, the side elements 44 may havedimensions approximately equal to 1.5×0.75 inches (i.e., width×flangelengths). The side elements 44 of the standard window section 24 may beformed with various lengths; however, certain embodiments may providefor the lengths to be between 48 and 120 inches, between 60 and 108inches, or about 72 inches. In some embodiments, the bottom element 42of the standard window section 24 may be formed in a generally standardsize of about 72 inches.

The above-described, individual elements of the standard window section24 may be secured together to form the rectangular frame by welding(e.g., fillet welds or spot welds) or riveting ends of the elementstogether. Specifically, ends of the top element 40 may be welded to theupper ends of the side elements 44. Because the top element 40 may beformed with a smaller width than the side elements 44 (e.g., 1.25 inchesversus 1.5 inches), the ends of the top element 40 may be receivedwithin the channels of the side elements 44 and welded therein. Thelower ends of the side elements 44 may be positioned against the uppersurface of the primary section of the z-channel of the bottom element 42and welded to the ends of the bottom element 42.

In some embodiments, the standard window section 24 may further includea horizontally-extending center element 46 that extend between the sideelements 44 and is positioned below the top element 40 and above thebottom element 42. In some embodiments, the center element 46 may beformed as an elongated section of steel or other metal c-channel, withthe channel facing upward towards the top element 40. In someembodiments, the center element 46 may have dimensions approximatelyequal to 1.25×0.75 inches (i.e., width×flange lengths). The centerelement 46 of the standard window section 24 may be formed with a lengththat generally corresponds with the length of the top element 40. Insome embodiments, the center element 46 of the standard window section24 may be formed in a generally standard size of about 48 inches. Theends of the center element 46 may be welded to the side elements 44 at aposition along the lengths of the side elements 44. Because the centerelement 46 may be formed with a smaller width than the side elements 44(e.g., 1.25 inches versus 1.5 inches), the ends of the center element 46may be received within the channels of the side elements 44 and weldedtherein. In certain embodiments, the one or more gusset plates 48 may beused to increase the strength of the connection between the centerelement 46 and the side elements 44. Similarly, gusset plates 48 may beused to increase the strength of the connection between the top elements40 and the side elements 44. Such gusset plates 48 may be welded inplace to the elements of the standard window section 24.

The center element 46 may be positioned about midway between the lengthof the side elements 44 so as to separate an interior space of the frameof the standard window section 24 into a window opening 50 and a loweropening 52. The window opening 50 comprises an open area that extendsbetween the center element 46 and the top element 40 (and between theside elements 44) and is configured to receive a window for thepassenger vehicle. Specifically, in some embodiments, the windows may besecurely received in the window opening 50 within the channels presentedby the top element 40, the side elements 44, and the center element 46.The center element 46 need not be positioned precisely midway betweenthe lengths of the side elements 44. For instance, the center element 46may be positioned closer to the bottom element 42 than the top element40, so as to present a larger window opening 50. For example, theprimary section of the center element 46 may be positioned about 42inches below the top element 40, such that the window opening 50 has avertical length of approximately 40.5 inches. The lower opening 52comprises an open area that extends between the center element 46 andthe bottom element 42 (and between the side elements 44). In someembodiments, the center element 46 may be position about 30 inches abovethe lower primary section of the bottom element 42, such that the loweropening 52 has a vertical length of approximately 30 inches.

In certain embodiments, the standard window section 24 may also includean angled support element 54 that extends within the lower opening 52 atangle between the side elements 44. The support element 54 may be usedto increase the strength of the standard window section 24. In someembodiments, the support element 54 may be formed from steel or othermetal rectangular or square tubing (e.g., galvanized steel). Forinstance, the support element 54 may be formed with dimensionsapproximately 1.25×1.25 (i.e., width×width). In more detail, the supportelement 54 may extend from a bottom corner of the lower opening 52 (at aposition approximate to where a lower end of a side element 44 isconnected to an end of the bottom element 42) to a top corner of thelower opening 52 (at a position approximate to where an end of thecenter element 46 is connected to one of the side elements 44). As such,in some embodiments, the support element 54 may extend at approximatelya 30 degree angle with respect to horizontal. Because the supportelement 54 may be formed with a smaller width than the side elements 44(e.g., 1.25 inches versus 1.5 inches), the ends of the support element54 may be received within the channels of the side elements 44 andwelded therein.

Beneficially, embodiments of the present invention provide for thestandard window section 24 to be manufactured in an efficient manner.Specifically, the c-channel and z-channel elements may be manufacturedfrom stock sheet metal in a metal-rolling process. Specifically, thegenerally flat stock sheet metal may pass through a rolling mill tore-form the sheet metal into the specific shapes required (e.g.,c-channels or z-channels). In some embodiments, the sheet metal maycomprise sheets of galvanized steel having a thickness of about 0.06inches. Nevertheless, it should be understood that the stock sheet metalmay have other thicknesses, and/or may be formed from other materials.Once the elements have been formed, the elements may be secured togetheras previously described to manufacture the standard window section 24.Although the above description illustrated certain of the elements ofthe standard window section 24 being formed from c-channels orz-channels, it should be understood that elements of othershapes/configurations may be used, such as square or rectangular tubing.

Turning to FIGS. 5 and 6, examples of contracted window sections 26 areillustrated. The contracted window sections 26 may include the samegeneral elements as the standard window section 24, including a topelement 40, a bottom element 42, a pair of side elements 44, a centerelement 46, and a support element 54. The side elements 44 of thecontracted window sections 26 may have lengths generally equal to thoseof the side elements 44 of the standard window section 24, such that thecontracted window sections 26 have generally the same height as thestandard window section 24. However, in some embodiments, the contractedwindow sections 26 may be formed with a width that is less than thewidth of the standard window section 24. For instance, each of the topelement 40, the bottom element 42, the center element 46, and thesupport element 54 of the contracted window sections 26 may be shorterthan the corresponding elements in the standard window section 24. Forinstance, as illustrated in FIG. 5, in some specific embodiments, thetop element 40, the bottom element 42, and the center element 46 mayhave lengths that are about 36 inches. As such, the contracted windowsections 26 may have a width of approximately 36 inches. As such, thesupport element 54 may be positioned so as to form a 38 degree anglewith respect to horizontal. In other embodiments, as illustrated in FIG.6, the top element 40, the bottom element 42, and the center element 46may have lengths that are about 20 inches. As such, the contractedwindow sections 26 may have a width of approximately 20 inches. As such,the support element 54 may be positioned so as to form a 55 degree anglewith respect to horizontal. Nevertheless, it should be understood that,in certain embodiments, the contracted window sections 26 may havewidths other than 36 or 20 inches. With the contracted window sections26 having shorter widths than the standard window section 24, the windowopenings 50 of the contracted window sections 26 may have acorrespondingly-shorter width, such that shorter windows may be usedwithin the contracted window sections 24. It should be understoodhowever, that the heights of the window openings 50 of the contractedwindow sections 26 may generally correspond with the height of thewindow opening of the standard window section 24, such that the heightsof the windows within the contracted window sections 26 will begenerally the same as the height of the windows within the standardwindow section 24.

Turning to FIG. 7, an example of the support section 28 is illustrated.The support section 28 may include the same general elements as thestandard window section 24, including a top element 40, a bottom element42, a pair of side elements 44, a center element 46, and a supportelement 54. The side elements 44 of the support section 28 may have thelengths that are generally the same as the side elements 44 of thestandard window section 24, such that the support section 28 hasgenerally the same height as the standard window section 24. However, insome embodiments, the support section 28 may be formed with a width thatis smaller than the width of the standard window section 24 and/or ofthe contracted window sections 26. Specifically, each of the top element40, the bottom element 42, the center element 46, and the supportelement 54 of the support section 28 may be shorter than thecorresponding elements in the standard window section 24. For instance,in some specific embodiments, the top element 40, the bottom element 42,and the center element 46 may have lengths approximately 10 inches.Nevertheless, it should be understood that, in certain embodiments, thesupport sections 28 may have widths other than 10 inches. In addition,in some embodiments, the support sections 28 may not generally includewindows incorporated therein. As such, the window openings 50 of thesupport sections 28 may have an additional support element 54 extendingdiagonally therethrough. Such support elements 54 may be positioned soas to form a 69 degree angle with respect to horizontal. Furthermore, insome embodiments, the support sections 28 may have one or morehorizontally-extending connecting elements 58 extending between the sideelements 44, with such connecting elements 58 being used to increase thestrength of the support section 28.

Turning now to the main section 22, as illustrated in FIG. 8, the mainsection 22 may be comprised generally of a pair of standard windowsections 24 that are coupled together. As such, the main section 22 mayhave a height that generally corresponds with the height of the standardwindow sections 24 (e.g., 72 inches) and a width that is generally twicethe width of the standard window sections 24 (e.g., 96 inches). A pairof standard window sections 24 may be coupled together to form the mainsection 22 by positioning one of the side elements 44 from a firststandard window sections 24 adjacent to one of the side elements 44 froma second standard window sections 24. Specifically, the exterior-facingsurfaces of the primary elements of the c-channels (i.e., the surfacesopposite the channels) of the side elements 44 from the pair of standardwindow sections 24 may be positioned adjacent to each other such thatthe exterior-facing surfaces are in contact with each other. As such,the standard window sections 24 may be secured together by spot welding(or, alternatively, fillet welding or riveting) the side elements 44together, as is illustrated by the spot weld 59 of shown in FIG. 9. Asis commonly known, spot welding is a process of joining two pieces ofmaterial by heating the material via an applied electric current. Theheat generated by the electric current passing through the two pieces ofmaterial will melt the material, so as to join the material together inthe form of a weld when the melted material cools and solidifies. Themain section 22 may include a plurality of spot welds (e.g., every fourinches) along the lengths of the adjacent side elements 44 of thestandard window sections 24 so as to secure the standard window sections24 together.

In some embodiments, however, the main section 22 may not include a pairof bottom elements 42, as would generally be included in a pair ofstandard window sections 24. Instead, the main section 22 may include asingle bottom element 60 that extends horizontally between the outerside elements 44 of the adjacent standard window sections 24. As withthe bottom elements 42, the bottom element 60 may comprise an elongatedsection of steel or other metal z-channel (e.g., galvanized steel), withuppermost extending portion of the bottom element 42 positioned on aninboard side of the main section 22. In some embodiments, the z-channelmay have dimensions approximately equal to 1.5×1.5×1.5 inches (i.e.,width×upward-extending flange length×downward-extending flange length).The bottom element 60 of the main section 22 may be generally formedwith a length that generally corresponds with, or is equal to, theoverall width of the main section 22 (e.g., about 96 inches). In someembodiments, the main section will also include a horizontally-extendingbase element 62 that extends between the outer side elements 44 of theadjacent standard window sections 24. The base element 62 may comprise asection of rectangular or square steel or other metal tubing (e.g.,galvanized steel). The base element 62 may have dimensions ofapproximately 1.5×1.5 inches (i.e., width×width). The base element 62may be secured to each of the outer side elements 44 via weld. The baseelement 62 may be spaced above the bottom element 60 between 4 and 12inches, between 5 and 10 inches, or about 6 inches. To facilitate suchpositioning of the base element 62, lower ends of the inner sideelements 44 of the adjacent standard window sections 24 may only extenddown as far as the base element 62, such that the side elements 44 donot extend below the base element 62. In such embodiments, the lowerends of the inner side elements 44 may be welded to an upper surface ofthe base element 62. Furthermore, each of the angled support elements 54that extend through the lower openings 52 may extend from the baseelement 62 (adjacent a position where the base element 62 is connectedto an outer side element 44) upwards at an angle of about 23 degrees tothe connection between the center element 46 and an interior sideelement 44.

As shown in FIG. 8, the bottom element 60 of the main section 22 may bea unitary piece of material. Such a main section 22 may be used as amodular wall section 20 on a passenger vehicle that does not include awheel well. However, as shown in FIG. 10, certain embodiments of thepresent invention provide for a main section 22 that includes a wheelwell 66 configured to providing a receiving area for a wheel of thepassenger vehicle. The wheel well 66 may be formed by removing a portionof the bottom element 60 and providing for two angled extension pieces68 to extend up from the bottom element 60 to the base element 62. Assuch, a wheel well 66 can be formed, which is configured to receive awheel of the passenger vehicle. In some embodiments, the wheel well mayhave a width of between 24 and 60 inches, between 32 and 48 inches,about 36 inches, or about 48 inches.

Finally, turning now to the seat rail 30, as shown in FIGS. 2-3, theseat rail 30 may extend generally horizontally across the inboard sideof the modular sidewall 20. The seat rail 30 may be positioned justabove the base element 62 and secured, via welds, to the inboardportions of the side elements 44 of each of the sections of the modularsidewall 20. As shown in the drawings, the ends of the seat rail 30 maybe secured to the inboard portions of the side elements 36 of the framesection 32. As such, a length of the seat rail 30 may correspond with,or be generally equal to, the overall length of the modular sidewall 20(e.g., between 8 and 32 feet, between 10 and 24 feet, between 12 and 20feet, or about 16 feet, or about 18 feet), as dependent on the length ofthe passenger vehicle. Although the following description of the seatrail 30 describes the use of spot welding or welding in general, itshould be understood that other securement components may be used inplace of spot welding, such as fillet welding, riveting, or the like.

As perhaps best shown in FIG. 11, the seat rail 30 may comprise a strutchannel 70 secured to a strut support 72. The strut channel 70 may beformed as a generally continuous section of steel or other metal and mayinclude a primary section 74 and a pair of flange sections 76 extendinggenerally orthogonally from the edges of the primary section 74 so as topresent a channel for receiving a seat support element 75 of a seat (notshown). Specifically, seats in passenger vehicles are generally providedin pairs so as to include an inboard seat and an outboard seat, whichare interconnected or integrally formed. Often, a support componentsextends upward from the floor to a bottom surface of the inboard seat,so as to at least partially secure the seats in place. In addition, theoutboard seat often includes seat support element 75 that extends in anoutboard direction, such that the seat support element 75 can bereceived within the channel presented by the strut channel 70 of theseat rail. In some embodiments, the seat support element 75 may besecured in place within the strut channel 70 via various methods ofsecurement, such as nut and bolt combinations, welding, and the like. Insome embodiments of the present invention, the flange sections 76 may beformed with inwards-curving lips to provide additional stiffness to thestrut channel 70 and to act as interference elements for maintaining theseat support elements 75 of the passenger vehicle's seats within thechannel. The strut channel 70 maybe formed in various sizes, dependingon the requirements of the passenger vehicle; however, in someembodiments, the primary section 74 may have a width between 1 and 3inches, between 1.25 and 2 inches, or about 1.6 inches. The flangesections 76 may extend from the primary element to form a length between0.25 and 2 inches, between 0.5 and 1 inches, or about 0.9 inches. Insome embodiments, the strut channel 70 may be formed by rolling a sheetof galvanized steel having a thickness of about 0.1 inches through aroll mill; although other thicknesses may be used.

The strut support 72 may be formed as a continuous section of materialthat comprises a primary section 78, a pair of double-hum flangesections 80 extending generally orthogonally from the edges of theprimary section 78 so as to present a channel, and a pair of end section82 that extend from the flange sections 80 in a direction generallycoplanar with the primary section 78. In some embodiments, the strutsupport 72 may be formed by rolling a sheet of galvanized steel having athickness of about 0.08 inches through a roll mill; although otherthicknesses may be used. As shown in the drawings, the double-hum flangesections 80 may be formed as a folded section of material, with thefolded portions of the section being folded upon themselves so as to bepositioned adjacent to and in contact with each other in an overlappingfashion. In some embodiments, the primary section 78 of the strutsupport 72 may be at least nominally larger than the primary section 74of the strut channel 70. For instance, the primary section 78 may have awidth between 1 and 3 inches, between 1.25 and 2 inches, or about 1.7inches. The flange sections 76 may extend from the primary element 74 toform a length between 0.25 and 2 inches, between 0.5 and 1 inches, orabout 0.7 inches. The end sections 82 may extend a length of between 0.5and 1.5 inches, between 0.75 and 1.25 inches, or about 1 inch.

As such, the strut channel 70 may be configured to be received withinthe channel presented by the strut support 72. The strut channel 70 maybe secured to the strut support 72 by positioning the exterior-facingsurface of the primary section 74 of the strut channel 70 (i.e., thesurface opposite the channel of the strut channel 70) into engagementwith the channel-presenting surface of the primary section 78 of thestrut support 72. In such a position, the flange sections 80 of thestrut support 72 may overlap at least portions of the exterior-facingsurfaces of the flange sections 76 of the strut channel 70. In someembodiments, the flange sections 80 may overlap at least 50 percent, atleast 60 percent, at least 70 percent, at least 75 percent, at least 80percent, or at least 90 percent of the exterior-facing surfaces of theflange sections 80 of the strut channel 70. The strut channel 70 can beheld in such a position via a plurality of spot welds located along thelength of the seat rail 30, with each extending through the adjacentprimary sections 74, 78 of the strut channel 70 and the strut support72. For example, in some embodiments, the seat rail 30 may include spotswelds every 4 inches along the length of the seat rail 30. With the seatrail 30 assembled as such described, the seat rail 30 can be secured tothe sections of the modular sidewall 20 as was previously described.

The modular sidewalls described above can beneficially be configured toact as sidewalls of passenger vehicles of various sizes. For example,the modular sidewall 20 illustrated in FIG. 2 can be used as part of theframe 10 of the passenger vehicle illustrated in FIG. 1. The modularsidewall 20 of FIG. 2 includes a main section 22, one standard windowsection 24, two contracted window sections 26 (one contracted windowsection 26 having a smaller width than the other), and one supportsection 28. Such sections are secured to each other and secured to theframe section 32, which includes the top element 34 and side elements36. As such, the modular sidewall 20 of FIG. 2 has a lengthapproximately equal to the total widths of each of the sections, i.e.,96 inches—main section 22; 48 inches—standard window section 24; 36inches—contracted window section 26; 20 inches—contracted window section26; 10 inches—support section 28. As such, the total length of themodular sidewall 20 of FIG. 2 is approximately 210 inches (i.e., 96inches+48 inches+36 inches+20 inches+10 inches). Thus, the modularsidewall 20 illustrated in FIG. 2 may be used on a passenger vehiclemanufactured with a passenger compartment that is about 17 or 18 feet inlength.

Beneficially, however, embodiments provide for the modular sidewall 20of the present invention to be used on passenger vehicles of differentseizes (i.e., having passenger compartments of different sizes). In moredetail, the specific configuration of the sections of the modularsidewall 20 can be reconfigured, added to, and/or subtracted from. Forexample, if it is required that the modular sidewall 20 is to be used ona passenger vehicle with a passenger compartment that is longer than 17or 18 feet, then one or more additional sections can be added to themodular sidewall 20 so as to increase the length of the modular sidewall20. As a specific example, a second standard window section 24 (i.e.,having a width of 48 inches) may be added to the modular sidewall 20 sothat the modular sidewall 20 can be used on a passenger vehicle with apassenger compartment having a length of 21 or 22 feet (it beingunderstood that the top element 34 of the frame section 32 may need tobe correspondingly lengthened). Alternatively, if it is required thatthe modular sidewall 20 is to be used on a passenger vehicle with apassenger compartment that is shorter than 17 or 18 feet, then one ormore of the sections can be removed from the modular sidewall 20 so asto decrease the length of the modular sidewall 20. As a specificexample, a contracted window section 26 (i.e., having a width of 36inches) may be removed from the modular sidewall 20 so that the modularsidewall 20 can be used on a passenger vehicle with a passengercompartment having a length of 14 or 15 feet (it being understood thatthe top element 34 of the frame section 32 may need to becorrespondingly shortened).

However, it should be understood that such above-provided examples arepurely exemplary, and embodiments of the present invention mayincorporate generally any configuration of individual sections withinthe modular sidewall of embodiments of the present invention. Broadly,the modular sidewall of embodiments of the present invention may includeat least the main section 22 and one or more additional sectionsselected from: the standard window sections 24, the contracted windowsections 26, and/or the support sections 28.

In addition to configuring the modular sidewall of embodiments of thepresent invention in a specific manner so as to be used on a passengervehicle of a specific size, certain individual sections of the modularsidewall may not be included so as make room for additional componentsof the passenger vehicle, such as entry door and wheelchair lift. Forexample, as shown in FIG. 12, the modular sidewall 21 includes a mainsection 22; however, as opposed to the modular sidewall 20 of FIG. 2,the modular sidewall 21 of FIG. 12 excludes a standard window section 24in place of an entry door opening 84 that can be used to receive a doorthat provides access to and egress from the passenger compartment of thepassenger vehicle. In addition, the modular sidewall 21 of FIG. 12excludes a contracted window section 26 and a support section 28 (e.g.,as are included on the modular sidewall 21) so as to provide liftopening 86 that is configurable to receive a wheelchair lift thatpermits handicapped user to enter and egress from the passengercompartment of the passenger vehicle. Thus, the specific arrangement ofindividual sections of the modular sidewall of the present invention canbe arranged so as to form a modular sidewall of a specified length, andfurthermore, the modular nature of the individual sections provides forone or more individual sections to not be included in the modularsidewalls so as to leave appropriate space for the integration ofvarious components of the passenger vehicle, such as doors, wheelchairlifts, etc.

When the particular configuration of the modular sidewall 20 isdetermined, the modular sidewall 20 can be assembled. Specifically,beginning with the frame section 32, individual sections may be securedto the frame section 30 in a sequential manner. For example, it may bebeneficial to start with a first end of the modular sidewall 20 and addthe sections one by one from the first end of the modular sidewall 20 toa second end. With reference to FIG. 2, the left-most contracted windowsection 26 may be first secured to the frame section 32. In someembodiments, such securement may be performed via spot welds, as waspreviously described. Beneficially, because the contracted windowsections 26 are formed, at least in part, from steel or other metalc-channels, such spot welding may be efficiently accomplished. Forinstance, the exterior-facing surface of the outer side element 44 ofthe contracted window section 26 may be positioned adjacent to the sideelement 36 of the frame section 32. With such a placement, the outerside element 44 of the contracted window section 26 may be secured tothe side element 36 of the frame section 30 via a plurality of sidewelds positioned along the length of the side element 44. In someembodiments, such spot welds may be positioned about every four inches.Next, the top element 40 of the contracted window section 26 may besecured to the top element 34 of the frame section 32. Theexterior-facing surface of the top element 40 of the contracted windowsection 26 may be positioned adjacent to the bottom surface of the topelement 34 of the frame section 32. With such a placement, the topelement 40 of the contracted window section 26 may be secured to the topelement 34 of the frame section 32 by a plurality of spot weldspositioned along the length of the top element 40. In some embodiments,such spot welds may be positioned about every four inches or so.

With the first individual element (i.e., the contracted window section26) of the modular sidewall 20 being secured in place, the remainingindividual elements may be secured in place in a similar manner. Withspecific reference to FIG. 2, the main section 22 may next be secured inplace, followed by the standard window section 24, followed by thesecond contracted window section 26, and finally followed by the supportsection 28. Beneficially, the sections of the modular sidewall 20 may besecured to each other in an efficient manner. Specifically, because theexterior-facing surfaces of the side elements 44 of adjacent sectionswill be in contact with each other (as shown in FIG. 9), spot welds canbe used to efficiently secure the individual elements together. In someembodiments, spot welds can be used about every 4 inches along thelengths of the side elements 44 being joined together.

Upon the individual sections of the modular sidewall 20 being securedtogether, the seat rail 30 may be finally added to the inboard side ofthe modular sidewall 20 as previously discussed. The exterior-facingsides of the primary section 78 (i.e., the sides opposite the channelpresented by the strut support 72) and of the end sections 82 provide alarge surface area for securement of the strut support 72 to thesections of the modular sidewall 20. In some embodiments, the seat rail30 will be secured to the inboard sides of the side elements 44. Toaccomplish such, one or more spot welds may be used to secure the endsections 82 to the side elements 44, where aligned with the sideelements 44. Beneficially, the flange sections 80 of the strut support,by overlapping the flange sections 76 of the strut channel 70, areconfigured to support the strut channel 70 securely within the channelpresented by the strut support 72. Thus, when a seat support element 75of a seat (not shown) that is included in the passenger vehicle isinserted within the channel presented by the strut channel 70, the strutchannel 70 supports the seat support element 75 in position, while theinward-curving lips function to retain the seat support element 75within the channel. Beneficially, because the flange sections 80 of thestrut support 72 overlap the flange sections 76 of the strut channel 70,the flange sections 80 function to provide additional support andstability to the strut channel 70. For instance, a greater amount ofdownward force can be applied to the strut channel, via seat supportelement 75, without the strut channel 70 bending or separating away fromthe modular sidewall 20. The large surface area provided by the endsections 82 also provide an enhanced connection to and stability of theseat rail 30.

After the modular sidewall 20 has been constructed, the modular sidewall20 can be secured to the passenger vehicle. Returning to FIG. 1, themodular sidewall 20 can be secured in position on the driver-side of thepassenger vehicle. Specifically, the bottom elements 42 of each of thesections (e.g., main section 22, standard window section 24, contractedwindow sections 26, and support sections 28) of the modular sidewall 20can be welded to the floor subassembly 12. The side elements 36 of theframe section 32 can be secured, via welding, to the respective backwall16 and cab subassembly 18 of the passenger vehicle. Finally, the topelement 34 of the frame section 32 can be secured, via weld, to the roofsubassembly 14. The modular sidewall 21 may be secured to the curb-sideof the passenger vehicle in a similar manner. Beneficially, with themodular sidewall 21 on the curb-side, the doors and the wheelchair liftare accessible for loading and unloading of passengers.

It is noted that the terms “substantially” and “about” may be utilizedherein to represent the inherent degree of uncertainty that may beattributed to any quantitative comparison, value, measurement, or otherrepresentation. These terms are also utilized herein to represent thedegree by which a quantitative representation may vary from a statedreference without resulting in a change in the basic function of thesubject matter at issue.

While particular embodiments have been illustrated and described herein,it should be understood that various other changes and modifications maybe made without departing from the spirit and scope of the claimedsubject matter. Moreover, although various aspects of the claimedsubject matter have been described herein, such aspects need not beutilized in combination. It is therefore intended that the appendedclaims cover all such changes and modifications that are within thescope of the claimed subject matter.

What is claimed is:
 1. A modular sidewall for a passenger vehicle, saidmodular sidewall comprising: an outer frame; and a plurality ofindividual sections configured to be secured together at least partiallywithin said outer frame, wherein said plurality of individual sectionsincludes— a main section presenting at least one window openingconfigured to receive a window, and a standard section presenting atleast one window opening configured to receive a window, wherein saidstandard section has a width that is smaller than a width of said mainsection.
 2. The modular sidewall of claim 1, wherein said plurality ofindividual sections further comprises a contracted section presenting atleast one window opening configured to receive a window, wherein saidcontracted section has a width that is smaller than the width of saidstandard section.
 3. The modular sidewall of claim 2, wherein saidplurality of individual sections further comprises a support section,wherein said support section is not configured to receive a window,wherein said support section has a width that is smaller than the widthof said contracted section.
 4. The modular sidewall of claim 1, whereinsaid plurality of individual sections are secured to said outer framevia one or more connection components, wherein said connectioncomponents are selected from rivets, fillet welds, and spot welds. 5.The modular sidewall of claim 1, wherein said plurality of individualsections are secured to each other via one or more connectioncomponents, wherein said connection components are selected from rivets,fillet welds, and spot welds.
 6. The modular sidewall of claim 1,wherein each of said plurality of individual sections comprises a topelement, a bottom element, and a pair of side elements extending betweensaid top element and said bottom element.
 7. The modular sidewall ofclaim 6, wherein said top element and said side elements are formed fromc-channel.
 8. The modular sidewall of claim 7, wherein the c-channelsare rolled from sheets of metal.
 9. The modular sidewall of claim 6,wherein said bottom element is formed from metal z-channel.
 10. Themodular sidewall of claim 6, wherein each of said plurality ofindividual sections further comprises a center element extending betweensaid side elements to present a window opening and a lower opening. 11.The modular sidewall of claim 6, wherein a portion of said bottomelement of said main section is removed to present a wheel well.
 12. Themodular sidewall of claim 1, wherein said outer frame comprises agenerally horizontal top element and a pair of side elements extendingvertically from ends of said top element.
 13. A modular sidewall for apassenger vehicle, said modular sidewall comprising: an outer frame; anda plurality of individual sections configured to be secured together atleast partially within said outer frame, wherein said plurality ofindividual sections includes— a main section presenting at least onewindow opening configured to receive a window, a standard sectionpresenting at least one window opening configured to receive a window, acontracted section presenting at least one window opening configured toreceive a window, wherein said standard section has a width that issmaller than a width of said main section, and wherein said contractedsection has a width that is smaller than the width of said standardsection.
 14. The modular sidewall of claim 13, wherein said plurality ofindividual sections further comprises a support section, wherein saidsupport section is not configured to receive a window, wherein saidsupport section has a width that is smaller than the width of saidcontracted section.
 15. The modular sidewall of claim 13, wherein saidplurality of individual sections are secured to said outer frame via oneor more connection components, wherein said connection components areselected from rivets, fillet welds, and spot welds, and wherein saidplurality of individual sections are secured to each other via one ormore connection components.
 16. The modular sidewall of claim 13,wherein each of said plurality of individual sections comprises a topelement, a bottom element, and a pair of side elements extending betweensaid top element and said bottom element.
 17. The modular sidewall ofclaim 16, wherein said top element and said side elements are formedfrom metal c-channel, and wherein said bottom elements are formed frommetal z-channel.
 18. A method of manufacturing a modular sidewall for apassenger vehicle, said method comprising the steps of: (a) providing anouter frame; (b) securing a plurality of individual sections togetherwithin the other frame to form the modular sidewall, wherein pluralityof individual sections includes— a main section presenting at least onewindow opening configured to receive a window, and a standard sectionpresenting at least one window opening configured to receive a window,wherein the standard section has a width that is smaller than a width ofthe main section; and (c) securing the modular sidewall to a side of thepassenger vehicle.
 19. The method of claim 18, wherein the plurality ofindividual sections are secured to the outer frame via one or moreconnection components, wherein said connection components are selectedfrom rivets, fillet welds, and spot welds, and wherein the plurality ofindividual sections are secured to each other via one or more connectioncomponents.
 20. The method of claim 18, wherein each of the individualsections comprises a top element, a bottom element, and a pair of sideelements extending between the top element and the bottom element,wherein the top element and the side elements are formed from metalc-channel, and wherein the bottom element is formed from metalz-channel.